RESIDENTIAL GAS WATER HEATERS

Transcription

1 Instruction Manual RESIDENTIAL GAS WATER HEATERS DIRECT VENT GAS MODELS NOT FOR USE IN MANUFACTURED (MOBILE) HOMES GAMA certifi cation applies to all residential gas water heaters with capacities of 20 to 100 gallons with input rating of 75,000 BTU/Hr. or less. For Your Safety AN ODORANT IS ADDED TO THE GAS USED BY THIS WATER HEATER. ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED. IF YOU ARE UNSUCCESSFUL, PLEASE WRITE TO THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER. KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED. PRINTED IN CANADA 0608 PART NO REV. B

2 SAFE INSTALLATION, USE AND SERVICE Your safety and the safety of others is extremely important in the installation, use and servicing of this water heater. Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important that the meaning of each safety message is understood by you and others who install, use or service this water heater. All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message and how to avoid the risk of injury. The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of potential exposure to such substances. WARNING: This product contains a chemical known to the State of California to cause cancer, birth defects, or other reproductive harm. This appliance can cause low-level exposure to some of the substances included in the Act. IMPORTANT DEFINITIONS Qualified Installer: A qualifi ed installer must have ability equivalent to a licensed tradesman in the fi elds of plumbing, air supply, venting and gas supply, including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of gas fi red water heaters. The qualifi ed installer must also be familiar with the design features and use of fl ammable vapor ignition resistant water heaters, and have a thorough understanding of this instruction manual. Service Agency: A service agency also must have ability equivalent to a licensed tradesman in the fi elds of plumbing, air supply, venting and gas supply, including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of gas fi red water heaters. The service agency must also have a thorough understanding of this instruction manual, and be able to perform repairs strictly in accordance with the service guidelines provided by the manufacturer. Gas Supplier: The Natural Gas or Propane Utility or service who supplies gas for utilization by the gas burning appliances within this application. The gas supplier typically has responsibility for the inspection and code approval of gas piping up to and including the Natural Gas meter or Propane storage tank of a building. Many gas suppliers also offer service and inspection of appliances within the building. 2

3 GENERAL SAFETY 3

4 SAFE INSTALLATION, USE AND SERVICE GENERAL SAFETY TABLE OF CONTENTS INTRODUCTION Preparing for the installation INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS TYPICAL INSTALLATION Get to know your water heater Replacement parts Mixing valve useage LOCATING THE NEW WATER HEATER Facts to consider about location Insulation blankets Ventilation for appliances located in confi ned spaces Vent termination INSTALLING THE NEW WATER HEATER Required ability Inspect shipment General Water piping T & P valve and pipe insulation (if supplied) Temperature-pressure relief valve Water (potable) heating and space heating Closed water system Gas piping Sediment traps Filling the water heater Venting High altitude installations Combustion air and ventilation Vent terminal clearances Vent connections Locating clearance hole for vent TABLE OF CONTENTS INTRODUCTION High rise vent arrangement Standard vent arrangement Securing vent termination assembly to the exterior wall. 17 Uncompressing the corrugated tubing Vent restricter plate Offset vent arrangement Condition Offset vent arrangement Condition LIGHTING & OPERATING LABEL TEMPERATURE REGULATION Temperature regulation FOR YOUR INFORMATION External damage Start up conditions Condensate Smoke/odor Thermal expansion Strange sounds Operational Conditions Smelly water Air in hot water systems High water temperature shut off system MAINTENANCE Venting system inspection Pilot and main burner Temperature & pressure relief valve Draining Cathodic protection - anode Anode rod maintenance Drain valve washer replacement LEAKAGE CHECKPOINTS Service TROUBLESHOOTING GUIDELINES NOTES WARRANTY Thank You for purchasing this water heater. Properly installed and maintained, it should give you years of trouble free service. Abbreviations Found In This Instruction Manual: CSA - Canadian Standards Association ANSI - American National Standards Institute NFPA - National Fire Protection Association ASME - American Society of Mechanical Engineers GAMA - Gas Appliance Manufacturer s Association UL - Underwriters Laboratories Inc. This gas-fi red water heater is design certifi ed by Underwriters Laboratories Inc. under American National Standard/CSA Standard for Gas Water Heaters ANSI Z CSA 4.1 (current edition). PREPARING FOR THE INSTALLATION 1. Read the General Safety section, page 3 of this manual fi rst and then the entire manual carefully. If you don t follow the safety rules, the water heater will not operate properly. It could cause DEATH, SERIOUS BODILY INJURY AND/OR PROPERTY DAMAGE. This manual contains instructions for the installation, operation, and maintenance of the gas-fi red water heater. It also contains warnings throughout the manual that you must read and be aware of. All warnings and all instructions are essential to the proper operation of the water heater and your safety. Since we cannot put everything on the fi rst few pages, READ THE ENTIRE MANUAL BEFORE 4 ATTEMPTING TO INSTALL OR OPERATE THE WATER HEATER. 2. The installation must conform with these instructions and the local code authority having jurisdiction. In the absence of local codes, installations shall comply with the National Fuel Gas Code ANSI Z223.1/NFPA. This publication is available from the Canadian Standards Association, 8501 East Pleasant Valley Road, Cleveland, OH If after reading this manual you have any questions or do not understand any portion of the instructions, call the local gas utility or the manufacturer whose name appears on the rating plate. 4. Carefully plan the place where you are going to put the water heater. Correct combustion, vent action, and vent pipe installation are very important in preventing death from possible carbon monoxide poisoning and fi res, see Figures 1 and 2. Examine the location to ensure the water heater complies with the Locating the New Water Heater section in this manual. 5. For California installation this water heater must be braced, anchored, or strapped to avoid falling or moving during an earthquake. See instructions for correct installation procedures. Instructions may be obtained from California Offi ce of the State Architect, 400 P Street, Sacramento, CA Massachusetts Code requires this water heater to be installed in accordance with Massachusetts 248-CMR 2.00: State Plumbing Code and 248-CMR For more information see next page.

5 INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS For all side wall terminated, horizontally vented power vent, direct vent, and power direct vent gas fueled water heaters installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above fi nished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfi ed: INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfi tter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfi tter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the sidewall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualifi ed licensed professionals for the installation of hard wired carbon monoxide detectors. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent fl oor level. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements provided that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed. APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and CSA certifi ed. SIGNAGE A metal or plastic identifi cation plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS. INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4. EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4: 1. The equipment listed in Chapter 10 entitled Equipment Not Required To Be Vented in the most current edition of NFPA 54 as adopted by the Board; and 2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building, or structure used in whole or in part for residential purposes. MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include: 1. Detailed instructions for the installation of the venting system design or the venting system components; and 2. A complete parts list for the venting system design or venting system. MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the fl ue gases, but identifi es special venting systems, the following requirements shall be satisfi ed by the manufacturer: 1. The referenced special venting system instructions shall be included with the appliance or equipment installation instructions; and 2. The special venting systems shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions. A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation. 5

6 TYPICAL INSTALLATION GET TO KNOW YOUR WATER HEATER TRIM PLATE (OUTSIDE) COLD WATER INLET PIPE REPLACEMENT PARTS Replacement parts may be ordered through authorized servicers or distributors. When ordering parts, provide complete model and serial numbers (see rating plate), quantity and name of part desired (as listed in Figure 1). Standard hardware items may be purchased locally. THERMAL EXPANSION TANK TRIM PLATE (INSIDE) INLET VALVE VACUUM RELIEF VALVE HOT WATER OUTLET PIPE ANODE UNION INLET DIP TUBE TEMPERATURE AND PRESSURE RELIEF VALVE INSTALL PER LOCAL CODES. INSTALL THERMAL EXPANSION TANK IF WATER HEATER IS INSTALLED IN A CLOSED SYSTEM. GAS PILOT & MAIN BURNER PILOT FLUE BAFFLE THERMOCOUPLE PIEZO ELECTRODE THERMOSTAT DISCHARGE PIPE (DO NOT CAP OR PLUG) GAS SUPPLY LINE GAS CONTROL KNOB MAIN MANUAL GAS SHUTOFF VALVE GROUND-JOINT UNION DIRT LEG WATER TEMPERATURE ADJUSTING DIAL DRAIN VALVE DRAINPAN GAS CONTROL 6 MAXIMUM AIR GAP FLOOR DRAIN OUTER DOOR ALL PIPING MATERIALS TO BE SUPPLIED BY CUSTOMER. FIGURE 1 6

7 MIXING VALVE USAGE NON-SCALD TEMPERING VALVE NON-TEMPERED WATER SUPPLY TEMPERED POTABLE WATER SHUT-OFF VALVE COLD WATER INLET NON-TEMPERED WATER RETURN SUGGESTED PIPING ARRANGEMENT FOR TOP CONNECTIONS TEMPERATURE-PRESSURE RELIEF VALVE GAS SUPPLY DISCHARGE PIPE (DO NOT CAP OR PLUG) CERTAIN MODELS ARE EQUIPPED WITH SIDE PLUMBING CONNECTIONS FOR SPACE HEATING. THE HOT AND COLD FITTING ASSEMBLIES (PART # ) CAN BE ORDERED THROUGH THE MANUFACTURER. DRAIN VALVE DRAIN PAN 6 MAXIMUM AIR GAP TO SUITABLE DRAIN FIGURE 2 This appliance has been design certifi ed as complying with American National Standard/CSA Standard for water heaters and is considered suitable for: Water (Potable) Heating and Space Heating: All models are considered suitable for water (potable) heating and space heating. HOTTER WATER CAN SCALD: Water heaters are intended to produce hot water. Water heated to a temperature which will satisfy space heating, clothes washing, dish washing, and other sanitizing needs can scald and permanently injure you upon contact. Some people are more likely to be permanently injured by hot water than others. These include the elderly, children, the infi rm, or physically/mentally handicapped. If anyone using hot water in your home fi ts into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap, then you must take special precautions. In addition to using the lowest possible temperature setting that satisfi es your hot water needs, a means such as a *Mixing Valve, should be used at the hot water taps used by these people or at the water heater. Mixing valves are available at plumbing supply or hardware stores. Consult a Qualifi ed Installer or Service Agency. Follow mixing valve manufacturer s instructions for installation of the valves. Before changing the factory setting on the thermostat, read the Temperature Regulation section in this manual. 7

8 LOCATING THE NEW WATER HEATER FACTS TO CONSIDER ABOUT THE LOCATION Carefully choose an indoor location for the new water heater, because the placement is a very important consideration for the safety of the occupants in the building and for the most economical use of the appliance. This water heater is not for use in manufactured (mobile) homes or outdoor installation. Sensors mounted in the drain pan that turn off the water supply to the entire home when water is detected in the drain pan. Water supply shut-off devices that activate based on the water pressure differential between the cold water and hot water pipes connected to the water heater. Devices that will turn off the gas supply to a gas water heater while at the same time shutting off its water supply. Also, the water heater must be located and/or protected so it is not subject to physical damage by a moving vehicle. Whether replacing an old water heater or putting the water heater in a new location, the following critical points must be observed: 1. Select a location indoors as close as practical to the vent terminal or location to which the water heater vent piping is going to be connected, and as centralized with the water piping system as possible. 2. Selected location must provide adequate clearances for servicing and proper operation of the water heater. Installation of the water heater must be accomplished in such a manner that if the tank or any connections should leak, the fl ow will not cause damage to the structure. For this reason, it is not advisable to install the water heater in an attic or upper fl oor. When such locations cannot be avoided, a suitable drain pan should be installed under the water heater. Drain pans are available at your local hardware store. Such a drain pan must have a minimum length and width of at least 2 in. (51mm) greater that the water heater dimensions and must be piped to an adequate drain. The pan must not restrict combustion air fl ow. This water heater must not be installed directly on carpeting. Carpeting must be protected by metal or wood panel beneath the appliance extending beyond the full width and depth of the appliance by at least 3 in. (76mm) in any direction, or if the appliance is installed in an alcove or closet, the entire fl oor must be covered by the panel. Failure to heed this warning may result in a fi re hazard. Water heater life depends upon water quality, water pressure and the environment in which the water heater is installed. Water heaters are sometimes installed in locations where leakage may result in property damage, even with the use of a drain pan piped to a drain. However, unanticipated damage can be reduced or prevented by a leak detector or water shut-off device used in conjunction with a piped drain pan. These devices are available from some plumbing supply wholesalers and retailers, and detect and react to leakage in various ways: Sensors mounted in the drain pan that trigger an alarm or turn off the incoming water to the water heater when leakage is detected. 8

9 Confi ned Space is a space whose volume is less than 50 cubic feet per 1,000 Btu per hour (4.8 cm per kw) of the aggregate input rating of all appliances installed in that space. VENT TERMINATION Before installing water heater determine placement of vent termination. INSULATION BLANKETS Insulation blankets available to the general public for external use on gas water heaters are not necessary with this product. The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank water heaters. Your Water heater meets or exceeds the National Appliance Energy Conservation Act standards with respect to insulation and standby loss requirements, making an insulation blanket unnecessary. Should you choose to apply an insulation blanket to this heater, you should follow these instructions (See Figure 1 for identifi cation of components mentioned below). Failure to follow these instructions can restrict the air fl ow required for proper combustion, resulting in fi re, asphyxiation, serious personal injury or death. Make certain to observe vent location limitation, see Figures 3, 4 & 12. Minimum clearances between the water heater and combustible and noncombustible construction are: 0 in. (0mm) from sides, 0 in. (0mm) from back, 4 in. (102mm) from front of jacket to closet door and 20 in. (508mm) from top of jacket to combustible and noncombustible material. Minimum vent clearance: 1 in. (25mm)*. Provide 3 ft. (915mm) front clearance for servicing and adequate clearance between the jacket top & ceiling for servicing the fl ue area, see Figure 4. * Where the wall is combustible and the wall thickness is over 14 in. (356mm), 1 in. (25mm) clearance to combustible materials around the vent terminal is needed. The first 14 in. (356mm) is zero clearance. Do not cover the outer door, thermostat or temperature & pressure relief valve. Do not cover the instruction manual. Keep it on the side of the water heater or nearby for future reference. Do obtain new warning and instruction labels from the manufacturer for placement on the blanket directly over the existing labels. Make certain the vent locations comply with the National Fuel Gas Code ANSI Z223.1/NFPA 54 and/or local codes. There is some important information shown in Figure 12. For a second or more direct vent unit, the distance between vent terminals must be a minimum of 12 in. (305mm). VENTILATION FOR APPLIANCES LOCATED IN CONFINED SPACES FIGURE 4 FIGURE 3 9

10 INSTALLING THE NEW WATER HEATER REQUIRED ABILITY INSTALLATION OR SERVICE OF THIS WATER HEATER REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENSED TRADESMAN IN THE FIELD INVOLVED. PLUMBING, AIR SUPPLY, VENTING AND GAS SUPPLY ARE REQUIRED. INSPECT SHIPMENT There may be hidden damage caused in transit. Check to be certain all parts of the venting system, as listed below, are present. CAUTION!!! IF THERE ARE ANY DAMAGED PARTS, DO NOT INSTALL THIS WATER HEATER. REPORT ANY SHORTAGE TO YOUR DISTRIBUTOR OR DAMAGE TO YOUR CARRIER. GENERAL The installation must conform to these instructions and the local code authority having jurisdiction. In the absence of local codes, the installation must comply with the current editions of the National Fuel Gas Code ANSI Z223.1/NFPA 54. The code is available from the Canadian Standards Association, 8501 East Pleasant Valley Road, Cleveland, OH WATER PIPING This water heater shall not be connected to any heating systems or component(s) used with a non-potable water heating appliance. All piping components connected to this unit for space heating applications shall be suitable for use with potable water. Toxic chemicals, such as those used for boiler treatment shall not be introduced into this system. When the system requires water for space heating at temperatures higher than required for domestic water purposes, a tempering valve must be installed. Please refer to Figure 2 for suggested piping arrangement. Water supply systems may, because of such events as high line pressure, frequent cut-offs, the effects of water hammer among others, have installed devices such as pressure reducing valves, check valves, back fl ow preventers, etc. to control these types of problems. When these devices are not equipped with an internal by-pass, and no other measures are taken, the devices cause the water system to be closed. As water is heated, it expands (thermal expansion) and closed systems do not allow for the expansion of heated water. The water within the water heater tank expands as it is heated and increases the pressure of the water system. If the relieving point of the water heater s temperature-pressure relief valve is reached, the valve will relieve the excess pressure. The temperature-pressure relief valve is not intended for the constant relief of thermal expansion. This is an unacceptable condition and must be corrected. HOTTER WATER CAN SCALD: Water heaters are intended to produce hot water. Water heated to a temperature which will satisfy space heating, clothes washing, dish washing, cleaning and other sanitizing needs can scald and permanently injure you upon contact. Some people are more likely to be permanently injured by hot water than others. These include the elderly, children, the infi rm, or physically/mentally handicapped. If anyone using hot water in your home fits into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap, then you must take special precautions. In addition to using the lowest possible temperature setting that satisfi es your hot water needs, a means such as a *mixing valve, should be used at the hot water taps used by these people or at the water heater, see Figure 2. Valves for reducing point of use temperature by mixing cold and hot water are also available: It is recommended that any devices installed which could create a closed system have a by-pass and/or the system have an expansion tank to relieve the pressure built by thermal expansion in the water system. Expansion tanks are available for ordering through a local plumbing contractor. Contact the local water supplier and/or a service agency for assistance in controlling these situations. NOTE: To protect against untimely corrosion of hot and cold water fittings, it is strongly recommended that di-electric unions or couplings be installed on this water heater when connected to copper pipe. All gas piping must comply with local codes and ordinances or with the National Fuel Gas Code ANSI Z223.1/NFPA 54 whichever applies. Copper and brass tubing and fi ttings (except tin lined copper tubing) shall not be used. Consult a Qualifi ed Installer or Service Agency. Follow manufacturer s instructions for installation of the valves. Before changing the factory setting on the thermostat, read the Temperature Regulation section in this manual. 10

11 HOT WATER OUTLET UNION 3/4 SWEAT FITTING COLD WATER INTLET SHUTOFF VALVE UNION 3/4 SWEAT FITTING TEMPERATURE AND PRESSURE RELIEF VALVE FIGURE 6 Fit pipe insulation over the incoming cold water line and the hot water line. Make sure that the insulation is against the top cover of the heater. Fit T & P valve insulation over valve. Make sure that the insulation does not interfere with the lever of the T & P valve. Secure all insulation using tape. TEMPERATURE-PRESSURE RELIEF VALVE DISCHARGE PIPE (DO NOT CAP OR PLUG) DRAIN VALVE FLOOR DRAIN DRAIN PAN 6 MAXIMUM AIR GAP FIGURE 5 Figure 5 shows the typical attachment of the water piping to the water heater. The water heater is equipped with 3/4 NPT water connections. NOTE: If using copper tubing, solder tubing to an adapter before attaching the adapter to the cold water inlet connection. Do not solder the cold water supply line directly to the cold water inlet. It will harm the dip tube and damage the tank. T & P VALVE AND PIPE INSULATION (IF SUPPLIED) Remove insulation for T & P valve and pipe connections from carton. This heater is provided with a properly certifi ed combination temperature - pressure relief valve by the manufacturer. The valve is certifi ed by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment of materials as meeting the requirements for Relief Valves for Hot Water Supply Systems, ANSI Z21.22 CSA 4.4, and the code requirements of ASME. If replaced, the valve must meet the requirements of local codes, but not less than a combination temperature and pressure relief valve certifi ed as indicated in the above paragraph. The valve must be marked with a maximum set pressure not to exceed the marked hydrostatic working pressure of the water heater (150 psi = 1,035 kpa) and a discharge capacity not less than the water heater input rate as shown on the model rating plate. 11 For safe operation of the water heater, the relief valve must not be removed from its designated opening nor plugged. The temperature-pressure relief valve must be installed directly into the fi tting of the water heater designed for the relief valve. Position the valve downward and provide tubing so that any discharge will exit only within 6 in. (152mm) above, or at any

12 distance below the structural fl oor. Be certain that no contact is made with any live electrical part. The discharge opening must not be blocked or reduced in size under any circumstances. Excessive length, over 30 ft. (9.14m), or use of more than four elbows can cause restriction and reduce the discharge capacity of the valve, see Figures 5 or When the system requires water for space heating at temperatures higher than required for domestic water purposes, a tempering valve must be installed, see Figure 7 for suggested piping arrangement. No valve or other obstruction is to be placed between the relief valve and the tank. Do not connect tubing directly to discharge drain unless a 6 in. (152mm) air gap is provided. To prevent bodily injury, hazard to life, or property damage, the relief valve must be allowed to discharge water in quantities should circumstances demand. If the discharge pipe is not connected to a drain or other suitable means, the water fl ow may cause property damage. The Discharge Pipe: Shall not be smaller in size than the outlet pipe size of the valve, or have any reducing couplings or other restrictions. Shall not be plugged or blocked. Shall be of material listed for hot water distribution. Shall be installed so as to allow complete drainage of both the temperature-pressure relief valve, and the discharge pipe. Shall terminate at an adequate drain. Shall not have any valve between the relief valve and tank. The temperature-pressure relief valve must be manually operated at least once a year. Caution should be taken to ensure that (1) no one is in front of or around the outlet of the temperaturepressure relief valve discharge line, and (2) the water manually discharged will not cause any bodily injury or property damage because the water may be extremely hot. CLOSED WATER SYSTEM FIGURE 7 A closed system will exist if a back-fl ow preventer (check valve), pressure reducing valve, or other similar device is installed in the cold water line between the water heater and the street main (or well). Excessive pressure may develop due to the thermal expansion of heated water causing premature tank failure or intermittent relief valve operation. This type of failure is not covered by the limited warranty. An expansion tank may be necessary in the cold water supply to alleviate this situation, see Figure 1. Contact the local plumbing authority. If the temperature and pressure relief valve on the appliance discharges periodically, this may be due to thermal expansion in a closed water supply system. Contact the water supplier or local plumbing inspector on how to correct this situation. DO NOT PLUG THE TEMPERATURE AND PRESSURE RELIEF VALVE. GAS PIPING If after manually operating the valve, it fails to completely reset and continues to release water, immediately close the cold water inlet to the water heater, follow the draining instructions, and replace the temperature-pressure relief valve with a new one. WATER (POTABLE) HEATING AND SPACE HEATING 1. All piping components connected to this unit for space heating applications shall be suitable for use with potable water. 2. Toxic chemicals, such as those used for boiler treatment, shall NEVER be introduced into this system. 3. This unit may NEVER be connected to any existing heating system or component(s) previously used with a non-potable water heating appliance. Make sure the gas supplied is the same type listed on the model rating plate. The inlet gas pressure must not exceed 14 inch water column (3.5 kpa) for natural and propane gas (L.P.). The 12

13 minimum inlet gas pressure shown on the rating plate is that which will permit fi ring at rated input. All gas piping must comply with local codes and ordinances or with the National Fuel Gas Code ANSI Z223.1/NFPA 54 whichever applies. Copper and brass tubing and fi ttings (except tin lined copper tubing) shall not be used. If the gas control valve is subjected to pressures exceeding 1/2 psi (3.5 kpa), the damage to the gas control valve could result in a fi re or explosion from leaking gas. If the main gas line Shut-off serving all gas appliances is used, also turn off the gas at each appliance. Leave all gas appliances shut off until the water heater installation is complete. A gas line of sufficient size must be run to the water heater. Consult the current edition of National Fuel Gas Code ANSI Z223.1/NFPA 54 and your gas supplier concerning pipe size. There must be: A readily accessible manual shut off valve in the gas supply line serving the water heater, and A drip leg (sediment trap) ahead of the gas control valve to help prevent dirt and foreign materials from entering the gas control valve. A fl exible gas connector or a ground joint union between the shut off valve and control valve to permit servicing of the unit. Be sure to check all the gas piping for leaks before lighting the water heater. Use a soapy water solution, not a match or open fl ame. Rinse off soapy solution and wipe dry. Use pipe joint compound or tefl on tape marked as being resistant to the action of petroleum [Propane (L.P.)] gases. The appliance and its gas connection must be leak tested before placing the appliance in operation. The appliance and its individual Shut-off valve shall be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 pound per square inch (3.5 kpa). It shall be isolated from the gas supply piping system by closing its individual manual Shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 pound per square inch (3.5 kpa). Connecting the gas piping to the gas control valve of the water heater can be accomplished by either of the two methods shown in Figures 8 and 9. FIGURE 8 GAS PIPING WITH FLEXIBLE CONNECTOR. When installed at elevations above 7,700 feet (2,347 meters), input rating should be reduced at the rate of 4 percent for each 1,000 feet (305 meters) above sea level which requires replacement of the burner orifi ce in accordance with National Fuel Gas Code ANSI Z223.1/NFPA 54. Contact your local gas supplier for further information. FIGURE 9 GAS PIPING WITH ALL BLACK IRON PIPE TO GAS CONTROL. Failure to replace the standard orifi ce with a high altitude orifi ce when installed could result in improper and ineffi cient operation of the appliance, producing carbon monoxide gas in excess of safe limits, which could result in serious injury or death. Contact your gas supplier for any specifi c changes which may be required in your area. 13

14 SEDIMENT TRAPS FILLING THE WATER HEATER Never use this water heater unless it is completely full of water. To prevent damage to the tank, the tank must be fi lled with water. Water must fl ow from the hot water faucet before turning ON gas to the water heater. A sediment trap shall be installed as close to the inlet of the water heater as practical at the time of water heater installation. The sediment trap shall be either a tee fi tting with a capped nipple in the bottom outlet or other device recognized as an effective sediment trap. If a tee fi tting is used, it shall be installed in conformance with one of the methods of installation shown in Figures 8 and 9. Contaminants in the gas lines may cause improper operation of the gas control valve that may result in fi re or explosion. Before attaching the gas line be sure that all gas pipe is clean on the inside. To trap any dirt or foreign material in the gas supply line, a drip leg (sometimes called a sediment trap) must be incorporated in the piping. The drip leg must be readily accessible. Install in accordance with the Gas Piping section. Refer to the current edition of the National Fuel Gas Code ANSI Z223.1/NFPA 54. HOT WATER OUTLET UNION COLD WATER INTLET SHUTOFF VALVE UNION TEMPERATURE AND PRESSURE RELIEF VALVE To fi ll the water heater with water: 1. Close the water heater drain valve by turning the handle clockwise ( ). The drain valve is on the lower front of the water heater. 2. Open the cold water supply valve to the water heater. NOTE: The cold water supply valve must be left open when the water heater is in use. 3. To insure complete fi lling of the tank, allow air to exit by opening the nearest hot water faucet. Allow water to run until a constant fl ow is obtained. This will let air out of the water heater and the piping. 4. Check all water piping and connections for leaks. Repair as needed. VENTING NEVER OPERATE THE HEATER UNLESS IT IS VENTED TO THE OUTDOORS AND HAS ADEQUATE AIR SUPPLY TO AVOID RISKS OF IMPROPER OPERATION, FIRE, EXPLOSION OR ASPHYXIATION. DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND VENTILATING AIR. ADEQUATE AIR FOR COMBUSTION AND VENTILATION MUST BE PROVIDED FOR SAFE OPERATION. HIGH ALTITUDE INSTALLATIONS DISCHARGE PIPE (DO NOT CAP OR PLUG) Installations above 7,700 ft. (2347 m) require replacement of the burner orifi ce in accordance with the National Fuel Gas Code ANSI Z223.1/NFPA 54. Failure to replace the orifi ce could result in improper and ineffi cient operation of the appliance, producing carbon monoxide gas in excess of safe limits, which could result in serious personal injury or death. Contact your gas supplier for any specifi c changes which may be required in your area. DRAIN PAN DRAIN VALVE 6 MAXIMUM AIR GAP FLOOR DRAIN FIGURE 10 14

15 COMBUSTION AIR AND VENTILATION When determining the installation location for a direct vent water heater, snow accumulation and drifting should be considered in areas where applicable. VENT TERMINAL CLEARANCES The vent system must terminate so that proper clearances are maintained as cited in local codes or the current edition of the National Fuel Gas Code ANSI Z223.1/NFPA 54 as follows: FIGURE 11 Be sure venting is properly connected to prevent escape of dangerous fl ue gases which could cause deadly asphyxiation. *Minimum 9 in. (23 cm) for appliances with 10,000 btuh (3 Kw) to 50,000 btuh (15 Kw) inputs and 12 in. (30 cm) for appliances greater than 50,000 btuh (15 Kw) to a window or door that may be opened 12 in. (30 cm) from soffit Minimum 7 ft. (2.3 m) above public sidewalk or paved driveway (see footnote 2) * Minimum 2 ft. (61 cm) from outside corner * * * Minimum 18 in. (46 cm) 12 in. (30 cm) above grade or anticipated snow level Minimum 3 ft. (91 cm) within a height of 15 ft. (4.6 cm) above meter/regulator assembly Minimum 3 ft. (91 cm) clearance to service regulator vent outlet Minimum 12 in. (30 cm) under veranda, porch, deck or balcony (see footnote 1) Minimum 3 ft. (91 cm) above if within 10 ft. (3 m) horizontally to a mechanical air supply inlet Minimum 12 in. (30 cm) from sides, above or below a permanently closed window or door * Minimum 9 in. (23 cm) for appliances with 10,000 btuh (3 Kw) to 50,000 btuh (15 Kw) inputs and 12 in. (30 cm) for appliances greater than 50,000 btuh (15 Kw) to a non mechanical air supply inlet into building or combustion air inlet to another appliance VENT TERMINAL AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED 1. Permitted only if veranda, porch, deck or balcony is fully opened on a minimum of two sides beneath the floor. 2. A vent shall not terminate above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings. FIGURE 12 15

16 LOCATING CLEARANCE HOLE FOR VENT Cut a clearance hole, approximately 7 in. (178mm) in diameter, through the exterior wall for the vent assembly. The recommended height is 68 in. (1.72m) for 40 gal. models and 76 in. (1.93m) for 50 gal., 50 gal. Hi-Input and 75 gal. models, as measured from the hole center to bottom of water heater. The maximum height recommended is 80 in. (2.03m) or in compliance with Figure 16. Where the wall is combustible and the wall thickness is over 14 in. (356mm), 1 in. (25mm) clearance to combustible materials around the vent terminal is needed. The first 14 in. (356mm) is zero clearance. 7 in. (178mm ) DIAMETER (SEE TEXT) DV TERMINATION SAFETY COVER BOTTOM OF HEATER FIGURE 15 A Safey cover (see Figure 13) is available to prevent accidental contact with the vent terminal. Contact your Customer Service Department for ordering information. HIGH RISE VENT ARRANGEMENT When the height H (From vent terminal center line to bottom of heater) is over 80 in. (2.03m), it is a high rise vent arrangement. In this case the minimum distance D from the center of the water heater to the outside wall surface is 22 in. (560mm), and the maximum height of H is 12 ft. (3.66m). D FIGURE 13 H 10 in. (254mm) (REF) WALL THICKNESS VENT CONNECTIONS After the location for the vent terminal has been selected as outlined in Figures 3, 4 & 12, use the following illustrations for installation: TO BOTTOM OF HEATER FIGURE 16 FIGURE 14 16

17 STANDARD VENT ARRANGEMENT UNCOMPRESSING THE CORRUGATED TUBING 3.6 in. (91mm) 2.6 in. (67mm) 17 in. (432mm) MIN.,* 80 in. (2.03m) MAX. 2.1 in. (54.5mm) WALL 1. Pull the inner corrugated tube towards the water heater and leave some length over the water heater s center for bending. 2. Pull the outer corrugated tube toward the water heater and leave it 1 in. (25mm) shorter than the inner corrugated tube. 3. Make sure there are two springs evenly spaced at the bend in the tube. 4. Use metal hangers to keep venting level or with a slope upward from the heater to terminal. SPRING FIGURE 17 * If the horizontal distance is less than 30 in. (760mm), the restricter plate must be installed (see Figure 22). VENT ASSEMBLY The vent tube and terminal can be assembled as shown in Figure 18. There are springs fastened inside the corrugated tube. When the vent tubes are pulled to a required length, the springs will still be equally spaced. SPRING CLAMP H REDUCER FIGURE 20 Bend both the corrugated tubes toward the water heater s fl ue connection. FIGURE 18 SECURING VENT TERMINATION ASSEMBLY TO THE EXTERIOR WALL. Some models are supplied with trim plates which may be used to cover the holes in the wall (see Figures 1 and 19). Slide one trim plate (if supplied) over the outer corrugated tube, then insert the outer corrugated tube through the clearance hole from exterior wall. Secure the trim plate to the exterior wall, then secure the vent terminal to the exterior wall with 4 screw anchors (included) appropriate for the type of wall construction. Caulk the junction of the vent terminal base plate and the exterior wall with exterior type sealant (not included). Slide the trim plate (inside) over the outer corrugated tube and fasten the trim plate to the interior wall. Caulk the junction of the outer corrugated tube and the trim plate (inside) with suitable sealant. FIGURE 21 VENT RESTRICTER PLATE For short horizontal vent runs (see Figure 17) place the restricter plate over the fl ue tube reducer before connecting the inner corrugated tube to the fl ue tube reducer. DO NOT use the restricter plate if the horizontal run is greater than 30 in. (760mm). TRIM PLATE (INSIDE) SEALANT UPPER AIR INLET BOX RESTRICTER PLATE FLUE TUBE REDUCER FIGURE 19 TRIM PLATE (OUTSIDE) FIGURE 22 Pull and connect the inner corrugated tube to the water heater s fl ue tube reducer with hi-temp red silicone (included) and gear clamp. Make sure this connection is tight and leak proof. *The sealant between the inner corrugated tube and water heater s fl ue tube reducer must be hi-temp red silicone or other material suitable for 600 F (315 C) continuous service. 17

18 TOP VIEW 90 MAXIMUM BEND FIGURE 23 Apply hi-temp red silicone (included) around the collar on air manifold box. Pull corrugated vent tube all the way on to collar and secure with one sheet metal screw (approx. 3/4 in. (19mm) up from edge of vent tube. Pull gear clamp past screw and tighten. FIGURE 26 CONDITION 2: Where fl oor joists impede venting, a rise or drop to complete the vent termination is possible. All installations require 1 in. (25mm) clearance to combustibles. Note: A. The maximum horizontal vent length of 80 in. (2.03m) minus wall thickness should be considered when installing an offset vent arrangement. B. Do not combine condition 1 (Figure 26) with condition 2 (Figure 27) in the same installation. C. The maximum allowable drop from vent center-line to vent termination center-line (Figure 27) is 7.25 in. (184mm). >1 in. (25mm) >1 in. (25mm) FIGURE 24 Check the level or slope of the venting again, and adjust if required. SLOPE H SEE CHART 7.25 in. (184mm) MAX WALL 10 in. (254mm) (REF) MODELS RECOMMENDED MINIMUM H 40 gal. 68 in. (1.72m) 50 gal. 76 in. (1.93m) 50 gal. Hi-INPUT 76 in. (1.93m) 75 gal. 76 in. (1.93m) FIGURE 27 FIGURE 25 OFFSET VENT ARRANGEMENT CONDITION 1: Where a straight vent arrangement is impossible, a horizontal 90 degree maximum bend can be made. Use the water heater casing outer diameter as a template to form the corrugated tube. 18

19 FOR YOUR SAFETY READ BEFORE LIGHTING BEFORE LIGHTING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES A. This appliance has a pilot which is lit by a piezo-electric spark gas ignition system. Do not open the inner door of the appliance and try to light the pilot by hand. B. BEFORE LIGHTING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance. Do not touch any electric switch; do not use any phone in your building. Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. GAS CONTROL KNOB PIEZO IGNITOR LIGHTING INSTRUCTIONS FIGURE 'A' If you cannot reach your gas supplier, call the fire department. C. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or turn by hand, don't try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion. D. Do not use this appliance if any part has been underwater. Immediately contact a qualified installer or service agency to replace a flooded water heater.do not attempt to repair the unit! It must be replaced! FIGURE 'B' FIGURE 'C' THERMOCOUPLE PILOT GAS CONTROL THERMOSTAT DIAL "OFF" POSITION 1. STOP! Read the safety information above on this label. 2. Set the thermostat to lowest setting (PILOT LIGHTING). Turn thermostat dial fully clockwise until it stops. 3. Push the gas control knob down slightly and turn clockwise to "OFF". SEE FIGURE 'A'. NOTE: Knob cannot be turned from "PILOT" to "OFF" unless knob is pushed down slightly. Do not force. 4. Remove the outer burner door located below the gas control. 5. Wait five (5) minutes to clear out any gas. If you then smell gas, STOP! Follow "B" in the safety information above on this label. If you don't smell gas, go to next step. 6. This unit is equipped with a push button pilot ignitor, which is used to light the pilot. Locate the ignitor on the gas control. 7. Turn gas control knob counterclockwise to "PILOT". SEE FIGURE 'B'. 8. The pilot is located on the left side of the burner. It can be located by looking through the glass view port while pressing the piezo ignitor button several times. Look for a spark at the pilot location, Figure "D". TO TURN OFF GAS TO APPLIANCE 1. Turn the thermostat dial to lowest setting (PILOT LIGHTING) "PILOT" POSITION TOP KNOB 9. Once the pilot has been found, push the gas knob all the way down. Immediately press and release the pilot ignitor button continuously up to (10) times. If the pilot will not light, repeat steps (3) through (9). 10. Continue to hold the gas control knob down for about one (1) minute after the pilot is lit. Release the gas control knob and it will pop back up. Pilot should remain lit. If it goes out, repeat step (9). It may take several minutes for air to clear the lines before the pilot will light. If knob does not pop up when released, stop and immediately call your service technician or gas supplier. If the pilot will not stay lit after several tries, turn the gas control knob clockwise to 'OFF' and call your service technician or gas supplier. SEE FIGURE 'A'. 11. Once the pilot flame is established replace the outer burner door. 12. At arm's length away, turn gas control knob counterclockwise to 'ON'. SEE FIGURE 'C'. 13. Set thermostat to desired setting. 19 "ON" POSITION ELECTRODE FIGURE "D" DANGER: Hotter water increases the risk of scald injury. Consult the instruction manual before changing temperature. 2. Push gas control knob down slightly and turn clock-wise to 'OFF'. Do not force. SEE FIGURE 'A'.

20 TEMPERATURE REGULATION TEMPERATURE REGULATION HOT WATER CAN SCALD: Water heaters are intended to produce hot water. Water heated to a temperature that will satisfy space heating, clothes washing, dish washing, and other sanitizing needs can scald and permanently injure you upon contact. Some people are more likely to be permanently injured by hot water than others. These include the elderly, children, the infi rm, or physically/mentally handicapped. If anyone using hot water in your home fi ts into one of these groups or if there is a provincial, state law or local code requiring a specifi c hot water temperature at the tap, then you must take special precautions. Never allow small children to use a hot water tap, or to draw their own bath water. Never leave a child or handicapped person unattended in a bathtub or shower. It is recommended that lower water temperatures be used to avoid the risk of scalding. It is further recommended, in all cases, that the water temperature be set for the lowest temperature that satisfi es your hot water needs. This will also provide the most energy effi cient operation of the water heater. Figure 28 shows the approximate water temperatures produced at various thermostat dial settings. Short repeated heating cycles caused by small hot water uses can cause temperatures at the point of use to exceed the thermostat setting by up to 30 F (17 C). If you experience this type of use you should consider using lower temperature settings to reduce scald hazards. Valves for reducing point-of-use temperature by mixing cold and hot water are available (see Figures 2 & 7). Also available are inexpensive devices that attach to faucets to limit hot water temperatures. Contact a licensed plumber or the local plumbing authority. SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, TURN OFF THE MAIN MANUAL GAS CON- TROL VALVE TO THE APPLIANCE (SEE FIGURE 1). NOTE: A water temperature range of 120 F-140 F (49 C-60 C) is recommended by most dishwasher manufacturers. The thermostat of this water heater has been factory set at its lowest position (PILOT LIGHTING). It is adjustable and must be reset to the desired temperature setting to reduce the risk of scald injury. The mark ( ) indicative of approximately 120 F (49 C) is preferred starting point. Some provinces may have a requirement for a lower setting. Turn the water temperature dial clockwise ( ) to decrease the temperature, or counterclockwise ( ) to increase the temperature. Temperature Setting Time to Produce 2nd & 3rd Degree Burns on Adult Skin VERY HOT= approx. 160 F About 1/2 second C = approx. 150 F About 1-1/2 seconds B = approx. 140 F Less than 5 seconds A = approx. 130 F About 30 seconds = approx. 120 F More than 5 minutes LOW = approx. 80 F FIGURE 28 20